Plastic pallets are non-wood pallets typically used in food, pharmaceutical, and pool applications.
Detailed Definition
Plastic pallets are made from materials such as high-density polyethylene or polypropylene, using processes including injection molding, structural foam molding, thermoforming and rotational molding. They are chosen where hygiene, washability, consistent dimensions and long service life matter, such as food, pharmaceutical, automated and closed-loop operations. They usually cost more than wood up front, so they pay off mainly when they return and are reused many times. iGPS operates a US rental pool of plastic pallets.
Nestable, stackable and rackable designs
Nestable pallets have legs that fit into each other when empty, saving space on return trips, but they are generally not meant for racking. Stackable pallets have a solid bottom so loaded pallets can be stacked on the floor. Rackable pallets are designed to span rack beams and are often reinforced, sometimes with steel or composite inserts. Always check the maker's rated capacity for the support condition you will use: floor, stacked, or racked.
Export, hygiene and fire considerations
Because they are not wood, plastic pallets fall outside ISPM-15, which simplifies export. They can be washed and do not absorb liquids the way wood can, which is why they are common in food-grade and hygiene-controlled areas. Plastic pallets can, however, change fire protection requirements in a warehouse. Sprinkler standards such as NFPA 13 treat plastic pallets differently from wood unless they are listed as equivalent through recognized testing, so consult a fire protection engineer before switching.
When plastic is the wrong choice
One-way shipments, high loss rates and loads that need racking without a suitable rackable design all work against plastic. Damaged plastic pallets are usually ground and recycled rather than repaired.
Authoritative Sources
- Material Handling Institute (MHI): the largest US trade association for material handling, logistics, and supply chain technologies.
- FDA Food Safety Modernization Act (FSMA): the 2011 federal food safety law under which FDA issued rules including Sanitary Transportation of Human and Animal Food, which covers the sanitary condition of vehicles and transportation equipment.
Related Glossary Terms
Frequently Asked Questions
Do plastic pallets need ISPM-15 treatment for export?
No. ISPM-15 applies to wood packaging material made from raw wood, so pallets made entirely of plastic are outside its scope and need no treatment or IPPC mark. Check for any wood parts, though: wooden runners, blocks or dunnage used with a plastic pallet are covered and must be treated and marked. Some exporters choose plastic or other non-wood pallets for this reason, especially for one-way international loads.
Are plastic pallets required in food facilities?
No US rule requires plastic pallets. FDA rules for food manufacturing and sanitary transportation require equipment to be suitable, cleanable and kept in a condition that does not contaminate food, and wood pallets can meet that when they are clean and in good repair. Many food plants still use plastic pallets in processing and high-hygiene areas because they are easier to wash and inspect, and they set this out in their own food safety programs.